1. Organizing Production Equipment
Richard A. Wysk
IE450

2. Agenda What makes for good organization? Part families
Manufacturing cells
Read Chapter 18 on the web

3. Types of Manufacturing Layout
Process Layout
Product Layout
Cellular Layout

4. FUNCTIONAL LAYOUTS ARE INEFFICIENT
Lathe
Milling
Drilling L L M M D D D D L L M M
Grinding L L M M G G
Assembly L L G G A A
Receiving and
Shipping G G A A
PROCESS-TYPE LAYOUT

5. Process Layout Characteristics
Advantages
Deep knowledge of the process
Common tooling and fixtures
Most Flexible -- can produce many different part types
Disadvantages
Spaghetti flow -- everything gets all tangled up
Lots of in-process materials
Hard to control inter-department activities
Can be difficult to automate

6. PRODUCT LAYOUT Part #1 L L M D G A A Receiving L M G Part #2 L M D
Shipping
Part #3

7. Product Layout Characteristics
Advantages
Easy to control -- input control
Minimum material handling -- frequently linked to the next process
Minimal in-process materials
Can be more easily automated
Disadvantages
Inflexible -- can only produce one or two parts
Large setup
Duplicate tooling is required for all cells

8. CELLULAR LAYOUT
Cell #2
Cell #1 D D M I D I L
Cell #3 M M L L D M I

9. U-shaped cells
U-shaped cells avoid constant displacements to the start of the line and solves many of the island distribution problems. S1 S2 S3 S6 S5 S4

10. Cellular Layout Characteristics
Advantages
Control is simplified
Common tooling and fixtures
Flexible -- can produce many different part types - a part family??
Disadvantages
Setup ??
Need to know about many different processes

11. VOLUME VARIETY HIGH FLEXIBILITY TRANSFER PRODUCTION CAPACITY LINE
SPECIAL
SYSTEM
FLEXIBLE
MANUFACTURING
SYSTEM
VOLUME
MANUFACTURING
Cells
STD. AND GEN.
MACHINERY
LOW
HIGH
VARIETY

12. How are Cells Formed Good intuition Careful study
Group Technology (GT)
Production Flow Analysis (PFA)

13. Production Flow Analysis
A technique for forming part families based on Operation Routing Summaries
Several methods available. We will discuss 2 algorithms for PFF (Part Family Formation)

14. Let’s consider 5 parts (n) and 6 machines (m):
m = {Drill1, Drill2, Mill1, Mill2, Vbore1, Vbore2}
= {D1, D2, M1, M2, V1, V2}

15. Operation Routing Summary

16. Create a PFA matrix, Parts Machines = 101 102 103 104 105 Drill 1 1 11 1 1
Drill 1 1
Machines 2
Mill 1 1 1 = 1
Mill 1 1 2 VB 1 1 1 1 VB 1 2

17. King’s Algorithm (Rank Order Clustering)
Step#1
Calculate the total column weight for each column
Generate 2i å
" = i j m w 2
Machine# (i)
Part# (j)
101
102
103
104
105 i 2 1 D 1 1 1 2 1 2 D 1 1 4 2 3 M 1 1 1 8 4 1 M 1 1 16 5 2 V 1 1 1 32 6 1 V 1 64 2
(wj)
Done!
Sum: mi,j * 2i 42 52 10 84 42
for each column (wj)

18. #2. If Wj is in ascending order, go to step #3; otherwise, rearrange the columns to make Wj fall in an ascending order.
105
101 D 1 14 2 48 M V 28
103
101
105
102
104 å i V 32 wj 2 10 42 42 52 84
102
103
104

19. å = m 2 w #3. "i, calculate the total row weight, wi Sum: mi,j * 2j
for each row (wi) wi
103
101
105
102
104 D 1 1 1 14 1 D 1 1 48 2 M 1 1 1 14 1 M 1 1 48 2
Generate 2j V 1 1 1 1 28 1 V 32 2 2j 2 4 8 16 32
Done!

20. #4. If wi is in ascending order, stop
#4. If wi is in ascending order, stop. Otherwise, arrange rows to make Wi ascend.
103
101
105
102
104 1 1 1 D 1 1 1 1 M 1 M1 1 1 1 V 1 V1 1 V 2 1 1 D 2 D2 V2 1 1 M 2 V2

21. #5 Stop and make Cells and Part families
103
101
105
102
104 1 1 1 D 1 1 1 1 M 1 1 1 1 V 1 1 V 2 1 1 D 2 1 1 M 2

22. #5 Stop and make Cells and Part families
Part Family #1
Part Family #2
103
101
105
102
104
Cell #1 1 1 1 D 1 1 1 1 M 1 1 1 1 V 1 1 V 2
Cell #2 1 1 D 2 1 1 M 2

23. Discussion
Good rectangles mean that you have very distinctive part families
Cell formation
Volume / Floor space
Size of problems
How about King’s algorithm? Will it always work?
Are there problems with it?

24. DIRECT CLUSTER ALGORITHM
101
102
103
104
105 w i D 1 1 1 3 1 D 1 1 2 2 M 1 1 1 3 1 M 1 1 2 V 1 1 1 1 4 1 V 1 1 2
Step #1. For I, calculate the total no. of positive cells in row, i

25. Sort rows in descending order of the wi values
101
102
103
104
105 V 1 D M 2 w i 4 3 D1
No Change D2 V1 M2
No Change
Done!

26. Step #2. j, calculate the total # of positive cell in each column, j

27. Sort columns in ascending order.
101
102
103
104
105 V 1 1 1 1 1 D 1 1 1 1 M 1 1 1 1 D 1 1 2 M 1 2 V 1 2 3 2 3 3 3
Sort Complete!

28. Step #3. For i = 1 to n, move all columns j where mij = 1 to the left maintaining the order of previous rows.
Observe Elements of Row 1
102
101
103
104
105 V 1 1 1 1 1 D 1 1 1 1 M 1 1 1 1 D 1 1 2 M 1 2 V 1 2
Move Column 105 to the left and push column 104 back

29. For Rows 1,2 & 3: Move the 1’s to the left and push the columns with the zeroes back
Observe Elements of Rows 2 & 3
102
101
103
105
104 V 1 1 1 1 1 D 1 1 1 1 M 1 1 1 1 D 1 1 2 M 1 2 V 1 2
Move Columns 101, 103 & 105 to the left and push column 102 back

30. Observe Elements of Row 4
101
103
105
102
104 V 1 1 1 1 1 D 1 1 1 1 M 1 1 1 1 D 2 1 1 M 2 1 V 2 1
Move Column 102 to the left and push column 101 back

31. Observe Elements of Rows 5 & 6
102
101
103
105
104 V 1 1 1 1 1 D 1 1 1 1 M 1 1 1 1 D 2 1 1 M 2 1 V 2 1
Move Column 104 to the left and push column 102 back

32. 104
102
101
103
105 V 1 1 1 1 1 D 1 1 1 1 M 1 1 1 1 D 2 1 1 M 2 1 V 2 1
Step #3 Complete!!

33. Step #4. For j = m to 1, move all rows I, where mij = 1 to the top maintaining the order of the previous columns, wij
Observe Elements of Columns 101, 103 & 105: No Change can be made!!
Observe Elements of Column 102
104
102
101
103
105 V 1 1 1 1 1 D 1 1 1 1 M 1 1 1 1 D 2 1 1 M 2 1 V 2 1
Move Row D2 upwards and push row D1 down

34. Observe Elements of Column 104
102
101
103
105 V 1 1 1 1 1 D 2 1 1 M 1 1 1 1 D 1 1 1 1 M 2 1 V 2 1
Move Row D2 to the top and push row V1 down

35. Observe Elements of Column 104
102
101
103
105 D 2 1 1 V 1 1 1 1 1 M 1 1 1 1 D 1 1 1 1 M 2 1 V 2 1
Move Rows M2 & V2 upwards and push row V1 down

36. 104
102
101
103
105 D 2 1 1 M 2 1 V 2 1 V 1 1 1 1 1 M 1 1 1 1 D 1 1 1 1
Step #4 Complete!!

37. Step #5. If current matrix is the same as the previous, stop; else to go 3.

38. Identify Cells or potential Cells
104
102
101
103
105 D 2 1 1
Cell #1 M 2 1 V 2 1 V 1 1 1 1 1
Cell #2 M 1 1 1 1 D 1 1 1 1
Part Family #1
Part Family #2

39. Production Flow Analysis -SCOPE-
We learned two (and probably the most common) methods/algorithms for performing a Production Flow Analysis.
There are a host of other algorithms and methods which are used in Academics and in the Industry.
(contd..)

40. Production Flow Analysis -Organizational View-
Production Flow Analysis consists of 5 different analyses:
Company Flow Analysis
Factory Flow Analysis
Group Analysis
Line Analysis
Tooling Analysis
PFA defined by Prof. Burbidge in 1971

41. Company’s Goals
CFA (Analysis)
We get a SCHEME for the division of products and components, machines and facilities into factory sets